Electrical

Alternator

14 pole alternator puts out a 50% duty cycle on the R terminal (white wire) -- 7 pulses
per revolution (tach takeoff not used on Willow)

The alternator ratings are based on SAE standards -- 6,000 RPM alternator speed and
78°F temperature. The maximum temperature is 300°F. The efficiency of a high-output
alternator is around 49%. An automotive alternator is only around 30% efficient (Rodney
Knelly at Hehr)

The original pulley (8-609) measured at 2.7" x 7/16". The new pulley measures
2.2" x 1/2".

Belt is a Gates Green Stripe (notches on belt), No. 9412 (12.5/13mm x 1050mm) or NAPA
25-10455 (25 9412). On the belt is written 13A1040. The belt lifetime is between 300 and
400 hours. Replace every 300 hours.

To remove the pulley nut, an impact wrench (rented) is magic. The nut is 15/16".
Without an impact wrench, use a 5/16" hex key inserted into the center of the shaft
to lock it and then use a wrench on the nut. The nut should be tightened to around 50
ft-lbs.

Recommended alternator filters from Powerline:
Electrocube (800-516-1112) G2438 fluorescent light filter on the field, G2418-150 on the
power output.

Repair kit 13-113 (list $110). Rebuild the alternator every 3,000 hours. If the boat is
left standing in a salty environment, the alternator may not output a voltage. If so, sand
the slip rings to get rid of corrosion, sand the brushes, and reassemble. The alternator
does not have any type of over-temperature current fold-back internal to it.

Rebuilt old unit that failed after about 2,000 hours. The repair place said that
the bearings overheated due to too tight of a belt. They suggested tightening the belt
just enough to stop the pulley from being able to turn when gripped with my hand. Then,
run the engine until hot and adjust the belt again. The old unit is now a spare onboard.

.

Alternator Filter

Installed a low-pass LC filter from Newmar. Part number
150-A This filter is supposed to remove alternator
noise from the radios.

Battery Combiner

Hellroaring Technologies, Inc. Model
BIC-75150A S/N A01C3337 (5/01). This is wired to isolate the starting battery and the
boat runs everything on the house battery. The starting battery is only used for starting
the engine. Replaced the first unit that failed (internal MOSFET blown).

The Lectra/San circuit breaker (75 amps) is located in the engine compartment on the
port side.

Breaker

Amps

Mains

30

Water Heater

15

Battery Charger

15

Spare

50

AC Outlets

?

Breaker

Amps

Cabin Lights

15

Running Lights

15

Anchor Light

5

Mast Light

15

Deck Lights

15

Sump Pump

15

Water Pressure

15

Spare

50

Radar

15

Accessory

40

Breaker

Amps

Bilge Pump

15

Autopilot (AP)

20

Radio

40

Tri-color Light

10

Washdown

15

Instrument Lights

15

Refrigerator

15

Instruments

10

Stereo

10

Inverter

40

Pump Panel

Located under galley sink. This controls the pumps (and the fuses for) the
refrigeration pump, the freshwater pressure pump, and the galley seawater pressure pump.
The panel was custom made by M & I Systems
based on my .DXF design.

I had a problem with the 1893 lamps turning black (silver?) just running the
instruments overnight. I installed a diode in-line with the positive feed, which dropped
the voltage 0.7V and stopped the lamp problem.

To convert from candela to lumens:

Lumens = Candela * 2 * π * (1
- cos(θ/2))

θ in radians.

The following is the section from the COLREGs about lamp
brightness:

8. Intensity of lights

(a) The minimum luminous intensity of lights shall be
calculated by using

the formula:

I = 3.43 x 10

6 x T x D2
x K-D

where:

I is luminous intensity in candelas under service
conditions.

T is threshold factor 2 x 10

-7
lux.

D is range of visibility (luminous range) of the light in
nautical miles,

K is atmospheric transmissivity. For prescribed lights the
value of K

shall be 0.8, corresponding to a meteorological visibility
of

approximately 13 nautical miles.

Lightning Protection

The tip of the lightning rod should be at least 10" above what it is designed to
protect. In addition, all other objects should fall under a protective 90° cone from the
tip.

Use a rounded tip rod with a radius of curvature between 3/16" and 1/2".

Aluminum or stainless steel are fine.

A 3/8" rod with a flattened attachment point to the mast will suffice.

The bottle brush devices aren't any more effective than a plain, rounded rod.

From Dr. Charles Moore, New Mexico Tech

The rig is bonded to underwater through the engine (at least for now). Green 6 AWG wire
used throughout (2002).

Noise (EMF) Reduction

To reduce pump noise in the refrigeration pump:

Opened up the pump and put a 0.1 µF cap across the power leads at the brushes. Also,
put a reversed-bias diode across the capacitor to kill back-EMF. Also, connected the
ungrounded metal case to the power supply ground.

To reduce refrigeration hum in SSB:

Grounded unused conductors in thermistor lead to the metal chassis ground of the
refrigeration unit.

Towed Water Generator

Tricolor/Anchor Light

Orca Green Marine, model
LXTA-P. This is an LED-based combo light at the top of the mast. Measured
current @12V of 0.4A for either one being on. The anchor light turns off at
sunrise with a built-in photocell in the green sector.

The light has a waterproof connector on the bottom. The
mating cable is a Conxall Nano-Mizer 603ST2. The included cable has 24 AWG
wires. The contacts are gold-plated.

My original unit failed with water intrusion. OGM replaced
it under warranty 12/2008.

Wiring

ID

Color

AWG

Description

AP

Sheath

14

Circuit breaker "Autopilot" to autopilot

B0

B

6

Ground from battery charger to Link 2000 shunt

B1

R

6

Positive from battery charger to House Bank

B2

R

6

Positive from battery charger to Starting Battery

10

R

8

Starting Battery to fuse block FB2-3

11

R

8

House Bank to fuse block

12

R

10

Fuse block to Battery Combiner "C" (Starting Battery)

13

R

10

Fuse block to Battery Combiner "A" (House Bank)

14

R

10

Battery Combiner Ground to Fuse block

15

R

16

Fuse block to ground on sense resistors

16

R

6

Circuit breaker "Radio" to SSB/VHF

17

B

6

SSB/VHF to Link 2000 ground shunt

18

B

2/0

Engine block to Link 2000 ground shunt

19

R

2/0

Positive from House Bank to distribution stud

20

B

2/0

Negative from House Bank to Link 2000 ground shunt

21

R

2/0

Starter bank +

22

B

2/0

Starter bank -

23

R/B

16

Fuse box to fresh water pump

24

R/B

16

Fuse box to refrigeration pump, icebox fan

25

R/B

16

Fuse box to seawater pump

26

R/B

16

Power to fuse box for pumps

27

B

2

Lectra/San -

28

R

2

Lectra/San +

29

R

2

House + to Lectra/San circuit breaker

30

R/B

16

Anchor light

31

R/B

16

Steaming light

33

R/B

16

Deck lights

34

R/B

10

Tricolor

35

R/B

12

Lower navigation lights

36

P

16

Engine alarm connection

37

Br

16

Regulator power

B - black, R - red, P - purple, Br - brown

All green wires are for bonding. The 6 AWG wire is for lightning bonding and 8 AWG wire
is for cathodic bonding.